Reinforced concrete structures having formwork embedded therein



De 1 6 s. BENNETT D CONCRETE STRUCTURES HAVING MWORK EMBEDDED THEREIN REINFORGE FOR 5 Sheets-Sheet 1 Filed June 25, 1963 s. B NETT 3,223,373 REINFORCED CONCR STRUCTURES HAVING FORMWORK EMBEDDED THEREIN 5 Sheets-Sheet 2 3 6 9 51 6) l m u M w c Dec. 14, 1965 s. BENNETT REINFORCED CONCRETE STRUCTURES HAVING FORMWORK EMBEDDED 'IHEREIN 3 Sheets-Sheet 3 Filed June 25 1965 FIG? United States Patent 3,223,378 REINFORCED CGNfIRETE STRUCTURES HAV- ING FORMWORK EMBEDDED THEREIN Sydney Bennett, 33 Benwerrin Ave., Carss Park, near Sydney, New South Wales, Australia Filed June 25, 1963, Ser. No. 290,544 7 Claims. (Cl. 24915) This invent-ion has been devised to provide reinforced concrete structures, such as walls, beams, pillars, beam and pillar casings and the like.

One advantage resulting from the invention is that the formwork becomes an integral part of the structure and constitutes the reinforcement or part of the reinforcement of the structure.

Another advantage resulting from the invention isthat the surfaces of the structure or selected surfaces can be left in a form which facilitates the application of and bonding of a facing material thereon.

According to this invention a formwork is made of slats which are secured horizontal-1y on a frame in parallel spaced relationship at an acute angle downwardly with the lower edges projecting inwardly. Cement and aggregate is poured into the formwork and bonded therewith.

Several forms of the invention are described with reference to the annexed drawings wherein:

FIGURE 1 is a fragmentary perspective view of a formwork partially filled with concrete to constitute a load sustaining wall. In this construction the slats are positioned to prevent cement and aggregate flowing out between the slats in a pouring operation.

FIGURE 2 is a vertical cross section of a Wall formwork of the type shown in FIG. 1 but having the slats positioned to permit concrete to completely fill the spaces between the slats and to be retained during the setting period by sheets of a light material removably fixed to the formwork.

FIGURE 3 is a side elevation of the structure shown in FIG. 2.

FIGURE 4 is a fragmentary perspective view of a formwork partially filled with concrete to constitute a partition or like wall. Sheets of light material are fixed to the slats as described with reference to FIG. 2.

FIGURE 5 is a fragmentary perspective view of a slat holder.

FIGURE 6 is a fragmentary perspective view of a formwork to encase a steel core in the construction of a pillar. In this figure the slats are positioned to achieve the concrete formation described with reference to FIG. 1.

FIGURE 7 is a sectional elevation of the lower end of a pillar formwork. In this figure the slats are positioned to achieve the concrete formation described with reference to FIG. 2 and sheets of light material are fixed to the slats.

FIGURE 8 is a fragmentary perspective view of a formwork for the construction of a beam.

Referring to FIG. 1 the formwork for a load sustaining wall therein depicted is made of slats 9 which are fixed in a frame in parallel spaced relations-hip at an acute angle downwardly, that is with the inner edge 10 the lowest. The spaced relationship of the slats 9 is such that the lower (inner) edge 10 of each slat is a short distance below the plane of the upper edge 11 of the next lower slat 3,223,378 Patented Dec. 14, 1965 and the angle of inclination of the slats is such that there is a space between the lower edge of each slat and the upper edge of an adjoining slat through which cement and aggregate can flow. The lowermost slat 9:: may be positioned at approximately the opposite angle to that of the slats 9 as shown to provide a footing for the structure but this is not essential. The slats may be perforate.

While any slat holding frame may be incorporated a convenient frame which will form part of the reinforcement of the wall is shown in FIG. 1. It consists of vertical rods 12-12a joined by transverse tie rods 13 and longitudinal stays 13a. Slat holders are made of plate 14 (see FIG. 5) cut and bent to provide angled slat brackets 15 and books 16. The hooks 16 catch on the longitudinal stays 13a and the slats 9 seat on the brackets 15. The so assembled parts are secured together by known means, such as by welding.

Cement and aggregate of the usual wetness (slump) is poured into the formwork from the top or and preferably through the slats. Experiments have revealed an unexpected phenomenon, namely that the spacing between the slats determines the flow formation of the outer faces of the concrete. FIG. 1 shows approximately a spacing which will cause the cement to flow to near the outer edge of the slats 9 and to fill up the space between them roug ly as indicated at 17. The cement will not normally spill over the outer edge of the slats. The wall so formed can be troweled or otherwise treated as is known in the art. It will be appreciated that where the end of a wall is not bonded to or butted on to some other structure the end(.s) of the formwork as above described is covered by a removable plate during the pouring operation.

If a wall having a smooth surface is required (see FIGS. 2 and 3) in a pouring operation a slat supporting frame is made as aforesaid but the slat brackets 15 in the slat holders 14 are made to support the slats 9 in such greater spaced relationship that the inner edge 10 of one slat is above the plane of the upper edge 11 of the next lower slat. This formation permits a relatively free flow of cement between the slats. The term smooth is used herein to define a surface which is substantially planar. A sheet 18 of cardboard, plywood, plastic or the like light material is secured against the edges 11 of the assembled slats 9 by rods or channel members 19. The members 19 are held in place by soft metal strips 20. The strips are passed through holes formed in the cardboard, one end of the strips is bent and hooked onto a.

slat 9 and the other end is bent and hooked onto a member 19. The sheet 18 may be reinforced by wire or wire mesh as indicated at 21 held in position by soft metal strips such as 20a. In this case the cement and aggregate is poured from the top. Owing to the construction of the supporting formwork the cement pressure on the cardboard is infinitesimal and a smooth surface wall can be formed. After the cement has set the cardboard and its supporting structure is easily removed by cutting the strips 2040a where they project from the wall. It will be appreciated that both sides of the structure shown in FIG. 2 will be made identical but for clarity some parts as described above are shown on one side only. The lowermost slat 9a may be positioned at approximately the opposite angle to that of the slats 9 as shown to provide a footing for the structure but this is not essential.

Where relatively thin walls, such as partition walls are required the formwork is modified as shown in FIG. 4. The slat holding frame shown in FIGS. 1 and 2 is omitted and in its .place there is a frame consisting of vertical rods 21 and longitudinal stays 22. Slat holders as shown in FIG. 5 are mounted in pairs on the stays 22, and slats 9 are fixed thereon as aforesaid. For most purposes the slats are spaced as described with reference to FIG. 2 and removable cardboar sheets are fixed to the formwork in the manner described. The lowermost slat 9a may be positioned at approximately the opposite angle to that of the slats 9 as shown to provide a footing for the structure but this is not essential. Cement and aggregate is poured into the formwork and troweled or otherwise treated to complete the wall.

In the construction of a pillar consisting of a steel core and a concrete casing (see FIGS. 6 and 7) the formwork is conveniently made in two parts 23-24 so that they can be placed around a vertical structural member (core) 25 and interlocked one with the other. In this construction part 23 is constructed to surround three sides of the structural member 25, and part 24 is constructed to encase the other side. The frame consists of vertical rods 26 and horizontal stays 27. The ends of the horizontal stays or some of them are bent to form catches 28. The part 24 is constructed in the same manner to complete the frame. In this part the horizontal stays 27 or some of them have the ends formed into hooks 29 arranged to engage and interlock with the catches 28. Slat holders as shown in FIG, 5 are mounted on the stays 27 as described with reference to FIGS. 1 and 2 and slats 9 having the ends shaped to form close contact with adjoining slats are fixed on the holders. Cement and aggregate are poured in the manner described with reference to FIG. 1.

FIG. 6 is in substance, the construction shown in FIG. 1 applied to a pillar and FIG. 7 is likewise the construction shown in FIG. 2 applied to a pillar. In FIG. 7 the slat holding frame is the same as that shown in FIG. 6 and the same references are applied to such parts. The slat holders are constructed to hold slats in the relative positions shown in FIG. 2 and the cardboard sheets are secured to the formwork in the same manner. The lowermost slats 9a may be positioned at approximately the opposite angle to that of the slats 9 to provide a footing for the structure but this is not essential. The references used in FIG. 2 are applied to these parts.

For the construction of a beam (see FIG. 8) a slat holding frame is formed of longitudinal members (stays) 30 held in a square or rectangular or other desired assembly by appropriately bent rods 31. The longitudinal members may be of a size to constitute substantial load carriers and they may be twisted in the form of a helix as is known in the art. The slat holders for the beam are made of plate 32 cut and bent to provide angled slat brackets as aforesaid. However, the hooks of the previous described holders are omitted. In this construction the slat holders are secured to the rods 31 by metal strips 33.

The frame made as described in the preceding paragraph is placed on a moulding board or table 34 and the slats 9 are fixed to the slat holders which are located on the vertical sides only of the frame. In the construction of a beam it is generally desirable to provide a smooth surface. In order to achieve this the slats are positioned in the same spaced relationship as described with reference to FIG. 2. The sides of the slatted frame are covered by cardboard or like sheets 35 which are secured temporarily in position by vertical members 36 and longitudinal members 37. These members 36-37 are preferably channel members and they are held in place by footings 38 fixed to the table 34 and bridles 39. As an addition or an alternative to the bridles the vertical members 36 are held in place by soft metal strips 40 which are fixed in the same manner as the strips described in connection with FIG. 2. The longitudinal members 37 are held in a designed spaced relationship by sheet metal members 41 which have hooks 42 formed and shaped to embrace the longitudinal members 37. Temporary end plates 43 complete the formwork. The sheets 35 may be reinforced in the manner described with reference to FIG. 2. The cement aggregate mixture is poured into the open top of the formwork and the top surface is finished in the usual manner. It will be appreciated that trunks for designed uses can be incorporated in the formwork prior to pouring the cement.

I claim:

1. A reinforced concrete structure comprising the combination of a framework including spaced horizontal longitudinal stays,

spaced vertical brackets secured to said stays, each of said brackets having angled slat-supporting surfaces thereon and longitudinally extending spaced horizontal slats secured to said brackets on said angled supporting surfaces to complete said framework, said slats, when so secured, being in mutually parallel spaced relationship, located each at an acute angle downwardly, with the lower longitudinally edge projecting inwardly of said framework and the upper edge projecting outwardly therefrom,

the vertical spacing of the slats being such that the lower inner edge of a slat is a short distance from the plane of the upper outer edge of the next lower slat and the angle of inclination of the slats is such that spaces are provided between the lower edges of slats and the upper edges of adjoining slats, adapted for the flow of wet cement and aggregate mix therethrough and cement and aggregate poured into and bonded with said framework, surrounding said stays, and brackets and filling the said spaces between said slats to complete the reinforced concrete structure when set.

2. A reinforced concrete according to claim 1 in which the spacing of the slats is such that the lower inner edge of each slat is a short distance below the plane of the upper edge of the next lower slat.

3. A reinforced concrete structure according to claim 1 in which the spacing of the slats is such that the lower inner edge of each slat is a short distance above the plane of the upper edge of the next lower slat and a sheet of light material is removably secured against the outer edges of the assembled slats to confine the cement and aggregate as it is poured into the framework.

4. A reinforced concrete structure according to claim 1 in which said structure is in the form of a wall,

said framework includes spaced vertical rods secured to said stays, and

the said brackets are made of .plate cut and bent to provide said angled slat-supporting surfaces thereon.

5. A reinforced concrete structure according to claim 1 in which said structure is in the form of a pillar,

said horizontal stays are bent to surround a vertical structural member, said framework includes spaced vertical rods secured to said stays and said framework is made in two parts adapted to be interlocked together and shaped to surround a vertical structural member when interlocked.

6. A reinforced concrete structure according to claim 1 in which said structure is in the form of a beam having vertical sides and a horizontal bottom,

said framework includes spaced rods bent into the shape of the beam with vertical side portions joined by a horizontal bottom portion,

said horizontal longitudinal stays being fixed to said bent rods to form a beam frame having vertical sides and a horizontal bottom, said slat-holding brackets being secured to the vertical sides of the beam frame,

a moulding board removably located below said frame and sheets of light material removably secured against the outer edges of the assembled slats on the frame at the vertical sides of the beam frame, said moulding board and sheets adapted to receive and confine cement and aggregate as it is poured into said beam frame. 7. A reinforced concrete structure according to claim 1 in which said brackets are made of plate cut and bent to provide said angled slat-supporting surfaces at one edge thereon and to provide hooks at the opposite edge thereon, said hooks engaging said horizontal stays to secure these parts to each other.

References Cited by the Examiner UNITED STATES PATENTS 850,758 4/1907 Jackson 52314 Masters 52414 Edwards 52-342 Dickson 52342 DeBaun 52-342 Frati 52383 Hybinette 26442 Hillberg 52-647 FOREIGN PATENTS Austria.

5 M. 0. WARNECKE, Assistant Examiner. 

1. A REINFORCED CONCRETE STRUCTURE COMPRISING THE COMBINATION OF A FRAMEWORK INCLUDING SPACED HORIZONTAL LONGITUDINAL STAYS, SPACED VERTICAL BRACKETS SECURED TO SAID STAYS, EACH OF SAID BRACKETS HAVING ANGLED SLAT-SUPPORTING SURFACES THEREON AND LONGITUDINALLY EXTENDING SPACED HORIZONTAL SLATS SECURED TO SAID BRACKETS ON SAID ANGLED SUPPORTED SURFACES TO COMPLETE SAID FRAMEWORK, SAID SLATS, WHEN SO SECURED, BEING MUTUALLY PARALLEL SPACED RELATINSHIP, LOCATED EACH AT AN ACUTE ANGLE DOWNWARDLY, WITH THE LOWER LONGITUDINALLY EDGE PROJECTING INWARDLY OF SAID FRAMEWORK AND THE UPPER EDGE PROJECTING OUTWARDLY THEREFROM, THE VERTICAL SPACING OF THE SLATS BEING SUCH THAT THE LOWER INNER EDGE OF A SLAT IS A SHORT DISTANCE FROM THE PLANE OF THE UPPER OUTER EDGE OF THE NEXT LOWER SLAT AND THE ANGLE OF INCLINATION OF THE SLATS IS SUCH THAT SPACES ARE PROVIDED BETWEEN THE LOWER EDGES OF SLATS AND THE UPPER EDGE OF ADJOINING SLATS, ADAPTED FOR THE FLOW OF WET CEMENT AND AGGREGATE MIX THERETHROUGH AND CEMENT AND AGGREGATE POUNED INTO AND BONDED WITH SAID FRAMEWORK, SURROUNDING SAID STAYS, AND BRACKETS AND FILLING THE SAID SPACES BETWEEN SAID SLATS TO COMPLETE THE REINFORCED CONCRETE STRUCTURE WHEN SET.
 3. A REINFORCED CONCRETE STRUCTURE ACCORDING TO CLAIM 1 IN WHICH THE SPACING OF THE SLATS IS SUCH THAT THE LOWER INNER EDGE OF EACH SLAT IS A SHORT DISTANCE ABOVE THE PLANE OF THE UPPER EDGE OF THE NEXT LOWER SLAT AND A SHEET OF LIGHT MATERIAL IS DREMOVABLY SECURED AGAINST THE OUTER EDGES OF THE ASSEMBLED SLATS TO CONFINE THE CEMENT AND AGGREGATE AS IT IS POURED INTO THE FRAMEWORK. 